US3697289A - Automatic popcorn popping method - Google Patents

Automatic popcorn popping method Download PDF

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Publication number
US3697289A
US3697289A US875759A US3697289DA US3697289A US 3697289 A US3697289 A US 3697289A US 875759 A US875759 A US 875759A US 3697289D A US3697289D A US 3697289DA US 3697289 A US3697289 A US 3697289A
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Prior art keywords
pot
oil
corn
popping
opening
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US875759A
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Alan M Day
Gordon D Browning
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WESTERN ICEE Corp A CORP OF CALIFORNIA
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Compupop Inc
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    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/161—Puffed cereals, e.g. popcorn or puffed rice
    • A23L7/174—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough
    • A23L7/183—Preparation of puffed cereals from wholegrain or grain pieces without preparation of meal or dough by heating without using a pressure release device
    • A23L7/187—Discontinuously-working apparatus

Definitions

  • Previous popping machines have not been entirely successful in providing a salable product having the desirable qualities of uniform flavor, tenderness and appearance. These have varied depending upon factors such as operator ,judgmentcr machine limitations in measuring the amount of raw products in the supply hoppers, time length for each cycle, the temperature in the pot during a 'pop, controlofsteam" and waste oil effluent from the popperfand separationiof 'old maids from the popped corn. In these poppers the operation has not been failsafe such that tlie cycle is'in'terrup'ted should any of the supplies be insufficient for a popping cycle.
  • Another object is to provide a fully automatic machine for popping corn in heated seasoning oil.
  • Another object is to provide a popcorn popping machine having a closed pot throughout a series of popping cycles eliminating the possibility of contamination of a pop, injury to the operator, and efiiuent discharge into the display case.
  • Another object is to provide a popcorn popping machine having electronic sensing of corn and salt supplies, and with electronic controls for precise timing and temperature control for the various cycles to produce a uniformly popped corn product of superior quality.
  • Another object is to provide an automatic corn popper of the type described providing air feeding of raw corn from a lower supply bin to an upper hopper positioned for feeding a precise charge into the popping pot.
  • Another object is a corn popping machine with air drying of the corn hopper and salt supply while injecting a charge into the popper.
  • Another object is a corn popper providing a vacuum in a pot during the popping cycle to draw steam and vaporized Waste oil into a condenser While preventing the same from contaminating the display case and popcorn product.
  • Another object is to provide a self-cleaning condenser to condense steam and waste seasoning oil from the popper and prevent the same from escaping from the machine or surrounding room.
  • Another object is a popping machine providing air evacuation of the popped corn product from the popper into the display case.
  • Another object is a popping machine providing air evacuation of the popped corn with a trap for removing old maids from the product and directing them into a' chute for subsequent removal.
  • Another object is a popping machine having a rotary valve disc above the popper to gate material supplies supply source providing a relatively short seasoning melt;
  • Another object is a popping machine having an agitator blade in the pot with a configuration drawing the popped corn inwardly toward the center for efilcient airevacua tion.
  • Another object is a popping machine having aclo sed pot with the drive for the agitator spring-loaded from above and interfit'ting with the agitator blade in a connection affording simplified opening and closing of the lower hotplate and blade away from the upper of the pot and drive for cleaning-purposes.
  • Another object is a popping machine having a rotary valve disc positioned above the pot to control machine processes, and With control switches interlocked with the valve disc to generate control signals in a manner prevent ing any process from functioning out of order.
  • Another object is a popper machine having a seasoning oil metering device providing fail-safe operation and with a precise charge of oil measured by selectively adjusting: the level for oil discharge from the metering reservoir whereby the oil is pumped into the reservoir above a predetermined level, and drained through the adjustable opening until the precise oil quantity remains in the reservoir for injection into the pot.
  • Another object is a popping machine having a seasoning oil metering device which feeds an oil charge into the popper only when a sufficient amount of oil for the charge is available for the desired pop.
  • the invention provides a popping machine and method of operation with fully automatic functions controlled in accordance with a predetermined program providing an optimum popcorn product of uniform flavor, tenderness, and appearance.
  • the corn is popped in hot oil enabling the use of a lower. popping temperature.
  • a closed popping pot reducesthe possibility of contaminants mixing with the product and affords removal of objectionable steam.
  • the material supplies corn and salt precisely metered in a predetermined quantity for each popping cycle, and are conveyed into the pot by an air current removing objectionable moisture therefrom and providing a positive hopper air pressure at all times.
  • the raw corn isfed from a large bin at the base of the machine'upwardly to a supply hopper above the pot by an air conveyor.
  • Seasoning oil contained in a supply at the base of the machine is delivered upwardly to a metering reservoir above thepot by a pump in the oil supply through a telescoping supply tube and support.
  • Heating means are provided to melt that portion of the solidified oil adjacent the pump inlet and telescoping tube for rapid start-up.
  • An oil metering device is provided measuring the precise quantity of oil required for each pop by filling up above a predetermined level in the reservoir, drawing down the oil to a level which is vertically adjustable, and then injecting the charge of remaining oil into the pot.
  • the oil level -in the reservoir is electronically sensed to signal the control circuit for continued cycling, or oil resupply, as required.
  • Arotary valve disc is indexed in accordance with a predetermined program and exposes a series of inlets and outlets including the inlets for air, corn and salt supplies, outlet to the condenser, and produ ct outlet for communication between the pot interior and display case.
  • a deflector plate is disposed below the air inlet for directing the. air current into a path around the inner periphery of the pot for carrying the popped corn upwardly to a discharge tube for delivery to the display case.
  • the unpopped corn or old maids are removed from the popped corn by a trap and delivered through a discharge chute for subsequent removal.
  • the steam and vaporized oil are removed from the pot by a vacuum created by a venturi in a self-cleaning condenser.
  • a major portion of the steam is condensed within an. exit conduit having a dome disposed above a gutter receiving thecondensed water and preventing the same from draining back into the pot.
  • An agitator blade in the pot has a configuration with its leading edge defining a forward rake to sweep the popped corn radially inward for evacuation into the discharge opening.
  • the drive for the agitator includes a spring-biased driving shaft mounted from .above and interfitting with a socket in the agitator base permitting easy opening and closing of the agitator 4: a flavor and appearance, provide either continual popping or a selected number of pops at any desired rate, and automatically count the number of pops for supply and usage control.
  • FIG. 1 is a front elevation view of an automatic popcorn popping machine .em'bodyingfeatures of the invention. I
  • FIG. 2 is a side elevation view of the machine of FIG.
  • FIG. 3 is a sectional plan view taken along the line 3-3 of FIG. 1.
  • FIG. 4 is a front elevation view taken along the line 4-4 of FIG. 2. 1
  • FIG. 5 is an elevation cross-sectional schematic view of a component condenser element in the invention.
  • FIG. 6 is a top plan sectional view taken along the line 6-6 of FIG. '4.
  • FIG. 7 is a fragmentary section view of the corn-salt hopper taken along the line 7-7 of FIG. 6.
  • FIG. 8 is a sectional view of the hopper taken along the line 88 of FIG. 7.
  • FIG. 9 is a fragmentary elevation view, partially in.
  • FIG. 10 is a cross-sectional elevation view of the. popping pot and associated elements of the invention.
  • FIG. 11 is a fragmentary top plan view of the agitator and hot plate assemblies.
  • FIG. 12 is a side elevation view, with portions, removed for clarity, of the popping, machine showing features of the corn supply and air conveyor.
  • FIG. 13 is a partial front elevation view, with portions removed for clarity, illustrating the seasoning oil supply and-pump with telescoping support and feed tube and heater elements.
  • FIG. 14 is an elevationview to an enlarged. scaleof.
  • FIG. 15 is a bottom view of the oil pump of FIG. 14.
  • FIG. 16 is an elevation sectional view of the oil meter-.
  • FIG. 21 is a fragmentary sectional view of a modified form illustrating a trap for removing old maids from. the air current evacuating popcorn from the pot.
  • a preferred form of the automatic popcorn machine is illustrated generally at 10.
  • Popcorn machine 10 comprises a main frame or supporting structure 12 including a lower supplies section;
  • a central display case. 16 a popping pot assemblyv 18 depending into the case, and anuppertsection 20 con-" taming the systems control circuits, operating mechai msms, and metering devices with associated controlknobsj and indicator lights.
  • Lower supplies section 14 is provided at its front with:
  • Access door 24 opens forwardly forconvenience in filling a raw popcornfbin withinthe' frame,:. .ocltab le door or drawer 26 may be provided for safeguarding cash.
  • An electrical outlet 28 may be provided for powering accessory equipment.
  • An access door 30 is provided and hinges for outward swinging movement to provide access to the mechanical equipment located in the bottom of the frame and for removal of the old maids bin and condensate pan.
  • Display case 16 includes a front wall defined by a pair of outwardly pivoting transparent doors 32, 34, providing access to the interior of the case for bagging popcorn and cleaning purposes.
  • a forward pivoting door 36 is also provided below the transparent doors for removing popcorn.
  • the display case sides 38, 40 and back 42 are preferably transparent for customer attention and product appeal.
  • a suitable screen 44 is provided in the bottom of the display case to pass the fines and old maids downwardly into a chute leading into a bin for subsequent removal.
  • Popping pot 18, described in greater detail hereinafter, delivers the popped corn into the display case through cone 46 in an attention getting shower onto the bottom of the case.
  • Upper portion 20 includes on its front face a control panel 48 including the selector knobs and indicator lights to be presently described.
  • a lockable control cover panel 50 is slideable along the front face of panel 48 and, when locked in position, prevents unauthorized usage of the machine.
  • Raw corn storage and conveyor Referring to the cross-sectional elevation view of FIG. 4, elements of the raw corn storage and conveyor system are illustrated in greater detail.
  • a large corn supply bin 52 capable of storing up to 100 lbs. of corn, is mounted in a lower portion of frame 12.
  • the bin is provided with a trough-shaped bottom 54 directing the raw corn downwardly into air-conveyor device 56 which automatically delivers a supply of corn, as required, upwardly into corn hopper 58 disposed in upper section 20 above pot 18.
  • Air conveyor 56 includes a suitable blower 60 driven by a preferred electric motor 62. The blower draws inlet air through opening 64 and directs it through transverse conduit 66 upwardly through vertical conduit 68 passing along the rear wall of the display case, as best illustrated in FIG. 12.
  • Corn from bin 54 is delivered intermittently through the air stream from the blower by metering device 72 operated by a signal from the control circuit indicating that a resupply of hopper 58 is required.
  • Metering device 72 may be any suitable valving arrangement, and preferably comprises a conventional scroll or anger conveyor horizontally axised with an inlet opening at 74 communicating with bin 54 and with an outlet at 76 communicating with throat section 78 comprising a section of the air stream conduit.
  • Metering motor 80 driving the auger is actuated responsive to a corn resupply signal until terminated responsive to corn level sensors in hopper 58 indicating that a sufficient quantity of corn has been supplied for an additional charge of corn into the pot.
  • the upper section of vertical conduit 68 passing through display case 16 is preferably formed of a transparent material such as plastic affording an attractive display ofcorn delivery for public viewing.
  • the corn supply in bin 52 at the lowermost portion of the machine With the corn supply in bin 52 at the lowermost portion of the machine, reloading through access door 24 is more easily and conveniently accomplished as opposed to a corn supply location above the popper.
  • the lower corn storage location is cooler and thus does not dry the corn as fast, as opposed to a location closer to the warmer portion of the machine near the popper.
  • the air feed is a simple and inexpensive method of deliverying a relatively small amount of corn intermittently on a demand basis. Neither the auger metering device nor the air conveyor itself are injurious or damaging to the corn kernels.
  • Corn and salt hopper 58- Referring to FIGS. 7 and 8 hopper 58 is shownin greater detail.
  • the hopper is divided into a corn reservoir 82 and salt chamber 84 by means of center partition 86, although the two supply reservoirs could be separated into individual chambers.
  • the corn and salt supplies are in juxtaposition to simplify and improve injection of the charges into the popper, as described hereafter.
  • Corn reservoir 82 is closed at the top by upper Wall 90, at the sides by partition 86 and side wall 92, and at the ends by end walls 94, 96 converging together below to define a narrowed throat section 98.
  • the hopper is mounted by means of base 100 on top of a support plate 102 separating display case 16 from upper section 20.
  • Throat section 98 of the hopper is in vertical registry with an opening 104 provided in plate 102, and this opening in turn communicates with popping pot 18 upon a fill cycle of the rotary valve apparatus 106 of FIG. 18.
  • An inlet opening 108 is provided in end wall 94 of the corn reservoir communicating with conduit 70 of air conveyor 56.
  • An outlet 110 is provided in the other end wall 96 and communicates with an air outlet conduit 112.
  • a screen 114 is provided over opening 110 to retain the corn within the reservoir.
  • the level of corn in the reservoir is sensed by a pair of capacitor plates 116, 118 mounted at the desired level within the reservoir to respective side wall 92 and partition 86. As the corn fills within the reservoir and occupies the space between the capacitor plates, the capacitance across the plates changes. This actuates the control circuit through leads 120, 122 for terminating operation of the corn meter motor, and energizes the corn indicator light for continuation of the cycling operation in a mannot described hereinafter.
  • valve hole or opening 396 of valving apparatus 106 moves into alignment with hopper throat section 98.
  • the corn is swept into the pot from the hopper by both the action of gravity and a stream of air fnom air conveyor outlet 79 moving down through throat section 98 into the pot and exiting through the lower opening 124 of cone 46, as best seen in FIG. 10.
  • the continued air pressure in the hopper from air conveyor 56 insures an air flow into the pot preventing any effluent from entering and fouling the hopper. This continued air fiow, although principally effective during filling, provides insurance of a.
  • a charge of salt is then introduced into the pot from salt chamber 84.
  • the salt chamber is closed at its sides by partition 86 and side wall 126, and at its ends by end walls 94 and 96 coextensive with the corn reservoir.
  • the top of chamber 84 is provided with a fill hole 128, and the bottom is confined by housing provided with an opening 132 communica-ting with a charging valve 134.
  • a salt bin 136 is pivotally mounted at 138 within chamber 84. Bottomwall 140 of the bin slopes downwardly from the pivot point to a relatively small spout or opening 142. The spout is adapted to move into opening 132 and act as a funnel for filling the charging valve 134.
  • Bin 136 is yieldably biased by suitable means such as spring 144 upwardly within the salt chamber, or clockwise as viewed in FIG. 8.
  • a normally closed switch 146 is mounted on chamber wall 126 and is adjusted for contact with salt bin 136 for opening when the bin is in its upper position, and for closing when the bin pivots away.
  • Salt bin 136 preferably has a capacity on the order of 6 /2 pounds, adequate for from 75 to 100 pops. With the bin filled with salt, it will pivot counter-clockwise by gravity against the force of spring 144 to close switch 146,
  • Charging valve 134 comprises a spool-valve 148' axially slidable in housing 130 underneath salt chamber openir'ig'132 'bythe action of solenoid 1*50 operatively connected With valve stem 152.
  • a return spring 154 is provided at the'opposite end of valve stem 152 for returning valve 134 to the position illustrated for receiving a supply of salt from bin 136.
  • salt drains from spout 142 through opening chamber opening 132, and into cavity 156 formed between the lands of the spool valve.
  • the volume of this cavity is selected to provide sufiicient salt for one pop.
  • the salt draining through spoutv 142 will automatically stop after the cavity is filled to a level just above the lower edge of the spout.
  • a shield 158 comprises a section of a cylinder secured at one side to partition 86, and is adapted to slideably receivespool valve 148. The lower section of shield 158is cut away at 160 to allow the salt to drop through by gravity and be swept along by the air stream. This air injection of the salt into the pot serves to dry the salt and prevent fouling or sticking or the component elements, and at the same time insures that all of the salt in each charge completely enters the pot for popping.
  • the seasoning oil pump system includes a pump assembly 160 disposed Within a seasoning oil bucket or vessel 162 positioned at the bottom of frame 12 for easy replacement, as illustrated in FIGS. 4 and 13.
  • the pump assembly is adapted to intermittently pump a supply of oil on a demand basis from bucket 162 upwardly through feed line 164 into oil reservoir 166 mounted above support plate 102 and positioned for injecting an oil charge into pct 18, as explained hereinafter.
  • the preferred seasoning oil would be coconut oil, although other conventional popping oils may be used with the invention.
  • the seasoning oil useful with the invention solidifies at room temperature.
  • the invention provides a means for melting a small quantity of the oil required for a number of initial popping cycles without the necessity of melting the entire contents of the oil bucket. This provides a more rapid start-up of the machine, as well as requiring less power.
  • Pump assembly 160 is adapted to move downwardly on the surface of the solidified oil while guided by a telescoping feed line 168 and telescoping support 170, as best seen in FIG. 14.
  • a bracket 172 mounted on frame 12 supports the outer telescoping member 174 of feed line 168:,'andf outer, telescopingmember 176 of support 170
  • Feed'line 168 is a rigid conduit secured at its lower end to pump u' n it'f178", and slideably received at its upper end withinputer telescoping member 174.
  • telescopi g support 170 is mounted at its lower end to the pump unitan'dj' is slideably received at its upper end with' tele scoping member 176.
  • An O-ring seal 180 is mounted within the lower inner periphery of member 174 to proafluid-tight seal with feed line 168.
  • the telscoping tu be elim inates the requirement for flexible h osing which othe'rwise could kink and interfere with pump help n abs s en in IG- 5- he Pu p i z r nhy ansuitable electric, motor mounted for ovement Cwith the pump housingaon an uPWA dl-y. ergtending bracket 188.
  • the motor ismounte d at a "elevatitn-rv abQ e the spump unitflsothat the motor is clear,.,of the melted oil after the pumphas dropped toits lowermostposition.
  • the pump is driven from the motor by asuitabledriye shaft, not. shown, extending along bracket 188.
  • lift handle is raised until the lower end of pump unit 7 8 clears the bucket.
  • With thenewbucketin placethe is lowered until it rests on the seasoning .oil within he bucket.
  • heating elements 1 96Qand 19 8 which may be conventional electrical resistance-type heating. ele ments in suitable tubing'or the like andconnected in tih e control circuit. Lower heating element 196 i sifcoiled ina serpentine path for melting oil. atfithe base of the pump unit. The purpose is to bothrnel't' 'oil around pump inlet 184 for rapid start-up, andialsoto melt .a, path d wn through the seasoning oil a'sm oil is consumed and, the gradually moves downwardly; Heating.
  • element" 198 ezg tends vertically in a serpentine pathor the like along telescoping feed tube 168, and may be of the conventional electrical resistance-type heater.
  • the purpose of heater 198 is to both heat the oil within feed tube 168, which may have solidified after a lengthoftime following-a, previous pum ing cycle, and also to .melta path': through: any solidified oil which may be above pump housing 1'82 dur,- ing start-up so that pump operation can draw air d own, thus preventing pump cavitation.
  • theheatcr gradually melt the entire.oi1- inthe bucket so that the pump. moves downwardly through the oil to the bottom of the bucket.
  • a pair of normally closed limit switches. 200 202 are mounted on frame 172 adjacent telescoping support 1710 Switch 200 is connected to cut off the circuit to pump motor 532, and switch 202, resets the operating cycle, when the pump unit is raised to its uppermost position.
  • a switch-operating cam 204 mounted at the lowerend bracket 188 is in registry with and;operat es the switches 200, 202 in its raised position. This provides a safe fty feature so that the pump is automatically turned 01f when raised out of the bucket.
  • oil'reservoir166 includes a housing 216 defining a'cavity or sump 21-8Cclose'd at its upper end by cover plate 220.
  • Reservoir inlet 208 is con nected with oil feed line 164 by means of'fitting 222, and communicates with a transverse 'bore' 224 formedin the housing. Bore 224 in turncommu'nicates With a hollow level-adjusting tube-226 slideably' mounted in the ⁇ housing in" vertical bore 228'. Adjusting tube 226 isclos'e'd” at its upper end and retains a compression spring 230 func tioni'ng to yieldably urge tube 226"upvvardly draining hole or opening 232 "formed in the side of tube 226 prbvides communication between reservoir cavity 218*, the
  • Adjusting mechanism 234 is provided to selectivelyadjust the vertical position of tube 226 and thereby adjust the level of drain 232.
  • Adjusting mechanism 234 comprises an adjusting knob 236 adapted to turn shaft 238 threadably mounted in cover plate 220 directly above the end of tube 226.
  • a pivoting shoe 240 mounted on the end of shaft 238 bears against the end of tube 226.
  • a lock nut 242 is provided to lock the shaft and level adjustment tube in the selected position.
  • the adjustabl drain level of the invention is more accurate in charge measurement than previous methods employing pumps, etc. where temperature variation or inaccurate pump shut off affects filling volume.
  • the invention provides a degree of safety in automation wherein only a measured amount of oil can be displaced into the pot on each cycle without the possibility of overfilling or overpumping.
  • Reservoir outlet 210 is connected with overflow conduit 212 by means of fitting 244 and communicates with the reservoir cavity through bore 246.
  • a spring-loaded ball check valve 248 is provided to prevent trapped seasoning oil from hardening in the reservoir during shut-down.
  • Valve 248 includes a ball 250 yieldably urged upwardly by means of spring 252 within bore 224.
  • a drain plug 258 is provided for retaining spring 252 in position.
  • Check valve 248 is normally held in open position duimg shutdown by means of drain shaft 260 contacting ball 250 at its end and yieldably urging the same downwardly by means of spring 262 mounted below drain shaft housing 264.
  • Drain shaft 260 includes an upward extending portion 266 slideably mounted in housing 264 and connected at its upper end 268 with electrically operated solenoid 270. Throughout the operating cycles of the machine solenoid 270 is operated to draw drain shaft. 260 upwardly permitting drain valve 248 to close.
  • solenoid 270 is de-energized permitting the spring to urge drain shaft 260 downwardly andopen' valve 248. Any oil remaining in the reservoir w'ill drain through the valve and thus cannot solidify in the reservoir. This prevents the reservoir and metering device from' malfunctioning and permits rapid start-ups without the requirements of heating the entire metering assembly and solidified oil.
  • a dump valve "assembly 272, FIG. 17, is provided to direct the metered amount of oil into the popper at the cycle time as influenced by the control circuit.
  • the dump valve assembly includes a valve head 274 carried on valve stem 276 and yieldably urged into sealing engagement with valve seat 278 byspring means 280.
  • the valve stem in turn is connected at 282 withelectrically operated solenoid 284.
  • solenoid 284 When energized, solenoid 284 lifts valve head 274 from seat 278 to open communication between the reservoir cavity and bore 286 in registry with an oil inlet opening 288 formed in plate 102.
  • the oil inlet is at a radial/position clearing rotary valve apparatus 106 for directing oilinto pot 18 by gravital flow.
  • An oil level sensing device 290 is provided to sense oil level in the reservoir and signal the control circuit for cycle functions.
  • the sensors comprisethreehorizontal, vertical spaced capacitor plates 292, 294 and 206 positioned at predetermined levels within the reservoir. Electrical leads 300, Y302 and 304 attached to respective condenser plates signal the control circuit as the oil level rises above 'atleast two of the plates.
  • the control circuit will signal pump 178 to pump oil through inlet 208 and drainhole 232 to fill the reservoir.
  • the capacitors signalthe control-circuit to start the popping cycle.
  • the pump continues to fill the reservoir until the level rises above plate 296, and this signals the control circuit to" terminate'the-pumping operation- Should the pump fail to stop for any reason the overflow will harmlessly return tothe'oil bucket through outlet 210 and conduit 212.
  • control circuit is timed to shut 01f after 10 seconds of operation to prevent damage to the pump should the pump run dry. It has been found that approximately 5 seconds is suflicient time for the pump to fill reservoir 166.
  • the maximum extent of downward travel of level adjustment tube 226 is such that drain hole 232 is positioned so that a minimum setting of 4 ounces of oil will be injected.
  • the upper extent of tube 226 travel provides a maximum of 10 ounces of oil.
  • Popping pot and discharge apparatus Popping pot 18 is positioned in the display case below support plate 102 for receiving the corn, salt and oil charges, for discharging steam and waste oil upwardly into condenser outlet 306 for delivery to condensing system 308, for receiving inlet air through evacuation inlet 310, and for evacuating popcorn through outlet conduit 312 and downwardly into the display case through tube 46, as best seen in FIG. 10.
  • Pot 18 comprises a bottom hotplate and agitator assembly 314 pivotally mounted at 316 to a housing 318, shown as cylindrical, mounted below support plate 102 by suitable means, such as bolts 320. The lower edge of the housing is mounted in sealing engagement with a groove 322 provided in angular support rim 324.
  • Evacuation conduit 312 extends through an openmg 326 in housing 318 downwardly to an opening 328 radially centered in the pot and spaced above hot plate 314 at a height sufiicient to permit popped corn to be swept upwardly through the conduit by a stream of air.
  • Conduit 312 extends outwardly from the pot through an opening 330 provided in upper cylindrical portion 332 of cone 46, where it angles to a downwardly facing discharge outlet 334. Corn exiting from the pot through conduit 312 cascades downwardly through cone opening 124 into the display case.
  • Hot-plate and agitator assembly 314 includes a casting 336 of flat, circular configuration embedded with a suitable heating element 338, such as a conventional electric resistance element connected by suitable leads, not shown,
  • a lower cover plate 340 is secured beneath the hot plate as a precaution against injury to the operator.
  • Upper annular rim 342 of casting 336 is in sealing engagement with housing rim 324 preventing escape of steam and waste oil from the pot.
  • a locking mechanism 344 mounted on rim 342 at a diametral positron from pivot 316 secures hot-plate assembly 314 against housing nm 324 throughout a series of popping cycles. The locking mechanism prevents unauthorized or accidental opening of the pot during popping, inasmuch as it is not necessary to open the pot for either charging or popcorn removal. For cleaning purposes, locking mechamsm 344 15 released permitting hot-plate assembly 314 to pivot downwardly at 316.
  • a plurality of outwardly extending, generally flat blades 354, 356 are mounted for rotation with the hub in a clockwise direction as viewed in FIG. 11.
  • the sharpened forward edge of each blade has a radially outward forward rake with respect to the axis of rotation. This provides a radially inward sweeping action to move the popcorn towards hub 348 for more efiicient evacuation through conduit 312.
  • the lower base portion of hub 348 is provided with an outwardly flaring skirt 358 functioning to direct the stream of air:upwardly into conduit opening 328 during corn evacuation.
  • lAgitator assembly 346 is rotated by drive assembly 360 extending downwardly from above the pot.
  • the drive assembly includes a shaft 362 having a preferred hexagonal cross-sectional configuration and slideably looking with a hexagonal female socket 364 provided at the upper end of agitator hub 348.
  • Shaft 362 is spring-loaded from above by suitable means such as compression spring 366 mounted within a sleeve 368.
  • Sleeve 368 in turn is secured to a broached hexagonal nut 370 keyed for rotation with drive shaft 372 extending downwardly through a quill shaft 374 of drive assembly 376 provided for operating rotary valve apparatus .106.
  • Drive shaft 372 is driven from a preferred electric motor 378 during the popping cycle by suitable means, such as a worm gear arrangement, not shown.
  • the lower end 382 of hexagonal shaft 362 projects through an opening 384 of the evacuation conduit, and is aligned with agitator socket 364 for driving engagementwhen hot-plate assembly 314 is closed, as illustrated in FIG. 10.
  • downward pivotal movement of the hot-plate and agitator quickly uncouples drive assembly 360 at the socket connection.
  • the shaft and socket will lock in driving engagement where there is correspondence between their angular positions. If shaft 362 does not engage in the socket, it is urged upwardly against the spring which forces them in locking engagement upon start-up of agitator motor 378. As a result, any angular or vertical misalignment between the shaft and mating socket will not prevent engagement of the agitator drive, thus simplifying opening and closing of the pot for cleaning.
  • the rotary valve apparatus 106 provides an accurate valving of the various processes into and out of pot 18 in timed relationship with a pre-determined program under influence of the control circuit.
  • the valve arrangement of the invention provides a mechanical memory to assist the electronic system to prevent loss of cycle'position during power failure or accidental shut-01f.
  • the valve apparatus includes a generally flat valve plate or disc 386 mounted for rotation with drive assembly 376 within the top H of pot housing 318.
  • a mounting plate 388 supports the valve plate to a flange 390 of quill shaft 374 by suitable means, such as a plurality of mounting screws or the like.
  • Valve disc 386 extends outwardly with a radius suflicient to cover aseries of openings provided in the top of pot housing 318 and support plate 102-.
  • these openings include a condenser outlet opening 392 connected with condenser conduit 306, an air inlet 394 connected with evacuation inlet conduit 310, and opening 104 connected with throat section 98 of corn and salt hopper 58.
  • An opening or disc hole 396 is formed in disc 386 uncovering openings 104, 392 and 394 in accordance "with the circuit program.
  • a screen 393 covers opening. 392 and prevents corn from entering conduit 306.
  • Valve drive assembly 376 includes a gear 398- keyed to quill shaft 374, which in turn is journaled for rotation within an upstanding sleeve 400 mounted above opening 402 provided in support plate 102.
  • Gear 398 is driven by suitable means such as an electric motor 404 mounted on bracket 380 and in driving connection with the gear through a suitable pinion gear 406, or the like, as illustrated in FIG. 9.
  • a start switch 408 a fill switch 410, a cook switch 412, and an evacuation switch 414 are mounted on a suitable bracket, not shown, around the periphery of gear 398.
  • Start switch 408 is positioned on a radial line bisecting the angle between fill opening 104 and evacuation inlet 394.
  • Fill switch 410 is positioned on line with fill opening 104.
  • Cook switch 412 is positioned on line with condenser outlet opening 392.
  • Evacuation switch 414 is positioned on line with evacuation inlet 394.
  • switches 408, 410, 412 and 414 are illustrated connected in the control circuit for operating the circuit relays, timers and indicator lights, as explained in greater detail hereinafter.
  • blower 418 is energized to draw intake air from cone 46 and direct it into the pot through conduit 310 and opening 394.
  • A; deflector plate 430 preferably of a fiat, circular configuration, is mounted within the pot by suitable means, such as a bracket 432 secured to the outside of conduit 312 at a position spaced directly below inlet 394. Deflector, plate 430 functions to direct the incoming air stream outwardly and downwardly around the inside periphery of the pot in a sweeping motion.
  • Thin enhances the efliciency of popcorn evacuation so that the air stream sweeps the popcorn across the bottom of the hot-plate, upwardly into evacuation conduit 312, and downwardly through cone 46 into the display case.
  • the stream of air issuing from outlet 334 in cone is recirculated and drawn upwardly. through the blower intake.
  • valve plate 386 closes olf condenser outlet 392.
  • valve disc 386 After a filling cycle with the corn and salt charged" into the pot, motor 404 indexes valve disc 386 until valve hole 396 opens communication with condenser outlet 392,
  • cam roller 416 actuates switch 412- let 392 into condenser system 308.
  • motor 404 stops the valve disc with itsopening at the condenser outlet position until the corn in popped and the control circuit initiates the evacuation cycle.
  • Condensing system 308 is adapted to .draw the steam and waste oil effluent from the pot by vacuum, and to:
  • the condenser system comprises an upstanding shell 434 mounted at the rear of i frame 12. Effluent from the pot is directed through conduit 306 into an upper inlet header 436 communicating with a plurality of downwardly extending heat exchange" tubes 438.
  • the tubes 438 communicate at, their lower end with a chamber 440 for reversefiow upwardly along aplurality of upwardly extending. heat exchange tubes 442 discharginginto outlet header. 444 and outlet tube 446.
  • -A-partition 448 divides shell 434 into two air channels 450 and.;452 enclosing respectivetubes 442 and 438. Cooling air froma condenser blower 454, as best seen in FIG. 4, is supplied from within lower section 14 of the machine and directed into inlet opening 4560f shell 434. The cooling air is forced-upwardly for cooling and condensing the steam and waste oil..Opening 458 in partition 448 combines the flow from channel 452 with that of channel 450 for delivery through a venturi or narrowed throat section 460 ,adjacent the discharge end of tubes 442. The increased air flow and lowered static pressure at the venturi creates a vacuum within tubes 442 acting to draw the steamand waste oil through the condenser tubes from the pot i'n'theflow path illustrated in FIG. 5.
  • Condensed steam'and oil droplets forming on the inside surface of the condenser tubes drop downwardly by gravity to collect on the bottom of chamber 440 where it 'drains through outlet 462 into a removable condensate drain .pan 464.
  • FIG. '20 illustrates'a modified form embodying'a steam condenser, illustrated generally at 466.
  • Condenser 466 replaces outlet conduit 306 betweencondenser outlet 392 and condenser header 436 in the preferred form of FIG. 6, and functions to immediately condense steam as it leaves the pot. The water condensate is collected and drained away preventing its-return to the pot. This results in a-dryer popcorn havingimproved flavor and tenderness;
  • Condenser 466 comprises an upwardly extending tube section-468 mounted over condenser outlet 392 on support plate 102.
  • Conduit section 470 encloses at one end upper lip 472 of the, tube and extends downwardly therefrom to an outlet474 mounted to the inlet of condenser header 436 by. suitable fasteners provided on mounting flange 476.
  • a dome or cap 478 is mounted above an opening 480 provided in conduit-470directly above the tube.
  • Tube lip 472 is radially spaced inwardly from conduit end portion 482to.define a collecting gutter 484.
  • a conical screen 486 mounted above tube lip prevents kernels of corn from entering the condenser air stream.
  • an alternate; old jmaid removal system is indicated generally at 494.
  • This system comprises a kernel trap device 496 including a lower tubular portion 498 extending downwardly through an opening in support plate 102 into the display'case" and opening underneath at 499.
  • An upper I tube extension 500 projects. above plate 102 into upper machine sectionl 20.
  • 'Ehetrap may extend through an opening inIQPncover 502 with a transparent top cover or dome504 of a suitable materiaL'such as-Lucite plastic.
  • This provides an attractive display of popcorn moving upwardly during an evacuation cycle.
  • Popcorn issuing from the pot through evacuation conduit 312 enters the trap through inlet connection 506 and is deflected upwardly by means of partition 508.
  • This partition comprises a vertical section of a cone removably attached within trap 496 and with its small end adjacent inlet 506 and its large end 510 opening upwardly within the tube.
  • a lower section 512 of the partition is lockably hinged at 514 for cleaning purposes and extends downwardly in abutting relationship with a tubular chute 516 extending downwardly from the trap to direct the old maids into a bin 492 for subsequent removal.
  • the popped corn and old maids are directed upwardly through conduit 312, then into opening 506 of the trap.
  • the popcorn is deflected upwardly by partition 508 and carried in the channel between the tube and partition by the air stream until it cascades over upper end 510 and falls downwardly into the display case.
  • the velocity of the air stream is high enough to blow the popcorn upwardly but insuffie cient to lift the old maids, which instead are carried by gravity downwardly through opening 518 into chute 516.
  • Power at VAC is provided at 530 for operating various control elements including agitator motor 378, valve disc motor 404, corn meter motor 80, seasoning pump motor 532 operating pump 178, motor 420 for powering emptying or evacuation blower 418, salt fill solenoid 150, and total pop counter 536.
  • the voltage from source 530 also operates power supply 538 providing a suitable direct current control voltage, such as 26 VDC.
  • This voltage powers the R.F. generator 540 connected with both corn level capacitor plates 116, 118 and seasoning level plates 291, 294 and 296.
  • This DC voltage further powers the number of pops selector control 542 through relay 544 and provides an input 546 pump motor 532 to fill oil reservoir 166 responsive to a signal from seasoning level condenser plates 292, 294
  • Salt level switch 146 provides a signal to'ffand switch 552 for continued cycling only if sufiicient salt is in bin .136 for the followingpopping cycle.
  • the number of pops selector 542 also provides a signal into switch552 for recycling of the popping cycle only wherev the number of pops selected by the operator exceeds the total pop count received at input 557 following each energization of fill switch 410.
  • the recycle signal from selector 542 also triggers operation ofcorn'level detector 548.
  • The'seasoning temperature is measured by low *temperature limit switch 558 which directs a signal to'both seasoning level detector/ switch 544 and switch 552 when the temperature of the oil is high enough for pumping

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Abstract

THE METHOD FOR AUTOMATICALLY POPPING CORN IN HEATED SEASONING OIL. RAW CORN IS RED BY N AIR CONVEYOR TO A HOPPER ABOVE THE POPPING POT, AND AN AIR CURRENT IS USED FOR INJECTING A CHARGE OF CORN AND SALT INTO THE POT. SEASONING OIL IS METERED INTO THE POT BY AN ADJUSTABLE VALVE PROVIDING PRECISE VOLUME MEASUREMENT. THE POT REMAINS CLOSED THROUGHOUT A SERIES OF POPPING CYCLES. A VACUUM IS CREATED IN THE POT DURING THE POPPING CYCLE TO PREVENT EFFLUENT FROM DISCHARGING INTO THE DISPLAY CASE AND TO DRAW IT INTO THE CONDENSER.

Description

Oc 10. 19 A. M. DAY mL 3,697,289
AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 1s Shouts-Shoot 1 F 3 i ii B P (@2 ((J 5 Y INVENTOR.
44 F I g. AIanM. Day
"'- BY Gordon D. Browning I I 73/ m f Aftorneys Oct. 10, 1972 Y ETAL AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 13 Sheets-Sheet 2 5 W. m) 5 g S n y at O n e g H V m m F Mu R :Huh 3 4 V B 4| 4 mo w m m n I q |l||..l|||I||l| F m In A BY Gord 5%4 Oct. 10, 1972 M. DAY ETAL 3,697,289
AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 15 Sheets-Sheet 3 Attorneys Oct. 10, 1972. A. M. DAY ETAL AUTOMATIC POPCORN POPPING METHOD 13 Sheets-Sheet 4 Filed Nov. 12, 1969 INVENTOR. Alan M. Day BY Gordon Brownm 5 I 7) I f M Attorneys Oct. 10, 1972 v A M. DAY ETAL 3,697,289
AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 sheets-sheet 5 mvrsmons Alan M. Day
Attorneys By fidon .Browging Oct. 10, 1972 A. M. DAY ETAL AUTOMATIC POPCORN POPPING METHOD l3 Sheets-Sheet 6 Filed Nov. 12, 1969 n l. S m Wm! M; QR m m m s. W in v W n i m0 D 27 Nam n1 M m. QM. "mmwvfll/hw A G 7 IIIII 3 Nam Oct. 10, 1972 Filed Nov. 12, 1969 Fig. 13
A. M. DAY ETAL 3,697,289
AUTOMATIC POPCORN POPPING METHOD l3 Sheets-Sheet 7 Fig.l2
BY Gordon D.Browm'nq attorneys Oct. 10, 1912 M DAY ETAL 7 7 3,697,289.
AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 13 Sheets-Sheet 8 F i g. I5
INVENTORS Alan M. Day By Gordon D. Browning i Aflorneys I Oct. 10, 1972 DAY ETAL AUTOMATIC POPCORN POPPING METHOD 1?) Sheets-Sheet 9 Filed Nov. 12, 1969 Fig. I6
m .m w, n 9 WWW r O! WW8 m WD d7 m d l m A Oct. 10, 1972 DAY ETTAL 3,697,289
AUTOMATIC POPCORN POPPING METHOD Filed NOV- 12, 1969 13 Sheets-Sheet 10 I N VEN TORS Alan M. Day BY Gordon D. Browning M,WW
Filed Nov. 12, 1969 A. M. DAY AL AUTOMATIC POPCORN POPPING METHOD 13 Sheets-Sheet ll 5Z4 fJ-zs POPPER HEATER,
I C o i cf UNIT 542 TEMP. I 1 I 526 CONTROL 240 4- SWITCH VAC l o-- 1 i lzoivAc I m 522 i 568 54;
' I AGITATOR CONTAC CONTACTOR SWITCH CONTROL a 533 50L INTERLINKS J- 600 -26VDC POWER SUPPLY |2OVAC F ,r CORN CORN SWITCH 554 M f r sEAs. PUMP SEAS MOTOR LEVEL sEAs. M6 WLEVE CORN 1 ZZ-LC PLATES SALT LEVEL LEVEL PLATES L m RE 4. r GEN. 26 voc INVENTORS Alan M. Day F i 19A BY 6 rdon D.Brownmg g 0 1% W W f l i Z Attorneys Oct. 10, 1912 M, DAY HAL 3,697,289
AUTOMATIC POPCORN POPPING METHOD Filed Nov. 12, 1969 l3 Sheets-Sheet l2 7 I20 VAC "POP" 4M sw. 184
56. 570 4/4 v T. DELAY VALVE DISC 4 SWITCH START 04 1 1 T. DELAY T. DELAY FILL& COUNT @7' SWITCH 570 v 85 F POPS PER HR. T. 115 mm l SELECTOR i NUMBER OF 572 POPS SELECTOR 8 ON OFF CONTROL &
Fig. [9B
INVENTORS Alan M. Day y Gordon Brownin M J 7-) J AUTOMATIC POPCORN POPPING METHOD Alan M.'Day, Oaklandyand'Gordon D. Browning, Case tro Valley, Calif., assignors to Compupop, Inc., San
Leandro, -Calif.
Filed Nov. 12, 1969, Ser. No. 875,759
IntNCI. A231 1/18 US. CI. 99-81 5 Claims AliSTRACT OF 7 THE DISCLOSURE BACKGROUND AND OBJECTS OF THE 1 I INVENTION This invention relates to fautomatic popcorn popping machines. f i
A'u'torrlatic"popcorn popping "r nachines have been proided-forum inythea'tres," clubs, amusement parks, and
other establishments tosupply the publics demand' for popcorn. These machines, however, have many disadvantages and' 'limitations.'A majority of the conventional poppers must employ ho't 'air popping rather than the more desirable oil-popping."Operation of the prior art poppingmac'hines isnotentirely automatic in that many of the steps must be performed manually, requiring the presence ofan operator. Thus, certain of the machines require manual control, of filling the popper with corn, seasoning-oil and'saltf In thesemachines the pot must be openedforeach popjand this introduces the possibility ofcontaminants entering the" pot and mixing with the popped corn, as well "as the possibility of injury to the operator. Popping machines of the open-pot type also quickly lead to fouling and unsightliness of the display case after only'a few pops resulting from condensed steam-andwaste oil.
Previous popping machines have not been entirely successful in providing a salable product having the desirable qualities of uniform flavor, tenderness and appearance. These have varied depending upon factors such as operator ,judgmentcr machine limitations in measuring the amount of raw products in the supply hoppers, time length for each cycle, the temperature in the pot during a 'pop, controlofsteam" and waste oil effluent from the popperfand separationiof 'old maids from the popped corn. In these poppers the operation has not been failsafe such that tlie cycle is'in'terrup'ted should any of the supplies be insufficient for a popping cycle. Also, if the operationstopsdur'ing any cycle, there is no assurance the machine will tinue with'the correct cycle sequence upon' rs'tajrtk- Previously, saltiinjection" into the popper has been' a proble'rnf'and'conventional machines have not successfully metered the precise amount of. salt into the wri er t, mj re u ts-i Conventional popping: machines also do not lend them: Q
to a 'cont'inued series of popping cycles untended by an operator and they have no provision for selectively c i trdulj e ate of popping and the total number of in a"completelyautomatic process.
Accordingly, it is the object of this invention to provide A PatentedOct; 10, 1972 ice a popcorn popping machine which is fully automatic in operation and affords selective adjustment of the popping variables to produce a uniform popcorn product of the desired flavor and appearance.
Another object is to provide a fully automatic machine for popping corn in heated seasoning oil.
Another object is to provide a popcorn popping machine having a closed pot throughout a series of popping cycles eliminating the possibility of contamination of a pop, injury to the operator, and efiiuent discharge into the display case.
Another object is to provide a popcorn popping machine having electronic sensing of corn and salt supplies, and with electronic controls for precise timing and temperature control for the various cycles to produce a uniformly popped corn product of superior quality.
Another object is to provide an automatic corn popper of the type described providing air feeding of raw corn from a lower supply bin to an upper hopper positioned for feeding a precise charge into the popping pot.
Another object is a corn popping machine with air drying of the corn hopper and salt supply while injecting a charge into the popper.
Another object is a corn popper providing a vacuum in a pot during the popping cycle to draw steam and vaporized Waste oil into a condenser While preventing the same from contaminating the display case and popcorn product.
Another object is to provide a self-cleaning condenser to condense steam and waste seasoning oil from the popper and prevent the same from escaping from the machine or surrounding room.
Another object is a popping machine providing air evacuation of the popped corn product from the popper into the display case.
Another object is a popping machine providing air evacuation of the popped corn with a trap for removing old maids from the product and directing them into a' chute for subsequent removal.
Another object is a popping machine having a rotary valve disc above the popper to gate material supplies supply source providing a relatively short seasoning melt;
time during start-up by reducing the amount required to be melted and pumped to the oil metering device for an initial charge.
Another object is a popping machine having an agitator blade in the pot with a configuration drawing the popped corn inwardly toward the center for efilcient airevacua tion.
Another object is a popping machine having aclo sed pot with the drive for the agitator spring-loaded from above and interfit'ting with the agitator blade in a connection affording simplified opening and closing of the lower hotplate and blade away from the upper of the pot and drive for cleaning-purposes. Another object is a popping machine having a rotary valve disc positioned above the pot to control machine processes, and With control switches interlocked with the valve disc to generate control signals in a manner prevent ing any process from functioning out of order.
Another object is a popper machine having a seasoning oil metering device providing fail-safe operation and with a precise charge of oil measured by selectively adjusting: the level for oil discharge from the metering reservoir whereby the oil is pumped into the reservoir above a predetermined level, and drained through the adjustable opening until the precise oil quantity remains in the reservoir for injection into the pot.
Another object is a popping machine having a seasoning oil metering device which feeds an oil charge into the popper only when a sufficient amount of oil for the charge is available for the desired pop.
These and other objects and advantages of the invention will become apparent to those skilled in the art when the following specification is read in conjunction with the accompanying drawings.
SUMMARY OF THE INVENTION The invention provides a popping machine and method of operation with fully automatic functions controlled in accordance with a predetermined program providing an optimum popcorn product of uniform flavor, tenderness, and appearance. The corn is popped in hot oil enabling the use of a lower. popping temperature. A closed popping pot reducesthe possibility of contaminants mixing with the product and affords removal of objectionable steam.
and waste oil effiuent. The material supplies corn and salt precisely metered in a predetermined quantity for each popping cycle, and are conveyed into the pot by an air current removing objectionable moisture therefrom and providing a positive hopper air pressure at all times. The raw corn isfed from a large bin at the base of the machine'upwardly to a supply hopper above the pot by an air conveyor. Seasoning oil contained in a supply at the base of the machine is delivered upwardly to a metering reservoir above thepot by a pump in the oil supply through a telescoping supply tube and support. Heating means are provided to melt that portion of the solidified oil adjacent the pump inlet and telescoping tube for rapid start-up. As the oil is consumed, the pump melts additional oil and moves downwardly with the level of the solidified oil. An oil metering device is provided measuring the precise quantity of oil required for each pop by filling up above a predetermined level in the reservoir, drawing down the oil to a level which is vertically adjustable, and then injecting the charge of remaining oil into the pot. The oil level -in the reservoir is electronically sensed to signal the control circuit for continued cycling, or oil resupply, as required. Arotary valve disc is indexed in accordance with a predetermined program and exposes a series of inlets and outlets including the inlets for air, corn and salt supplies, outlet to the condenser, and produ ct outlet for communication between the pot interior and display case. A deflector plate is disposed below the air inlet for directing the. air current into a path around the inner periphery of the pot for carrying the popped corn upwardly to a discharge tube for delivery to the display case. In a modified form the unpopped corn or old maids are removed from the popped corn by a trap and delivered through a discharge chute for subsequent removal. Duringa popping cycle the steam and vaporized oil are removed from the pot by a vacuum created by a venturi in a self-cleaning condenser. In another modified form a major portion of the steam is condensed within an. exit conduit having a dome disposed above a gutter receiving thecondensed water and preventing the same from draining back into the pot. An agitator blade in the pot has a configuration with its leading edge defining a forward rake to sweep the popped corn radially inward for evacuation into the discharge opening. The drive for the agitator includes a spring-biased driving shaft mounted from .above and interfitting with a socket in the agitator base permitting easy opening and closing of the agitator 4: a flavor and appearance, provide either continual popping or a selected number of pops at any desired rate, and automatically count the number of pops for supply and usage control.
DESCRIPTION OF THE DRAWINGS FIG. 1 is a front elevation view of an automatic popcorn popping machine .em'bodyingfeatures of the invention. I
FIG. 2 is a side elevation view of the machine of FIG.
FIG. 3 is a sectional plan view taken along the line 3-3 of FIG. 1.
FIG. 4 is a front elevation view taken along the line 4-4 of FIG. 2. 1
FIG. 5 is an elevation cross-sectional schematic view of a component condenser element in the invention.
FIG. 6 is a top plan sectional view taken along the line 6-6 of FIG. '4.
FIG. 7 is a fragmentary section view of the corn-salt hopper taken along the line 7-7 of FIG. 6.
FIG. 8 is a sectional view of the hopper taken along the line 88 of FIG. 7.
FIG. 9 is a fragmentary elevation view, partially in.
cross section, taken along the line 9 -9 of FIG. 6.
FIG. 10 is a cross-sectional elevation view of the. popping pot and associated elements of the invention.
FIG. 11 is a fragmentary top plan view of the agitator and hot plate assemblies.
FIG. 12 is a side elevation view, with portions, removed for clarity, of the popping, machine showing features of the corn supply and air conveyor.
FIG. 13 is a partial front elevation view, with portions removed for clarity, illustrating the seasoning oil supply and-pump with telescoping support and feed tube and heater elements.
FIG. 14 is an elevationview to an enlarged. scaleof.
the oil pump and heater elements of FIG. 13.
FIG. 15 is a bottom view of the oil pump of FIG. 14.
FIG. 16 is an elevation sectional view of the oil meter-.
illustrating a steam condensor connected between the pot outlet and main condenser. Y
FIG. 21 is a fragmentary sectional view of a modified form illustrating a trap for removing old maids from. the air current evacuating popcorn from the pot.
DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to the drawings, and particularly to FIGS.
1-3, a preferred form of the automatic popcorn machine is illustrated generally at 10.
Popcorn machine 10 comprises a main frame or supporting structure 12 including a lower supplies section;
14, a central display case. 16, a popping pot assemblyv 18 depending into the case, and anuppertsection 20 con-" taming the systems control circuits, operating mechai msms, and metering devices with associated controlknobsj and indicator lights.
Lower supplies section 14 is provided at its front with:
various access doors for resupplying the corn and oil supplies and removal of waste products. Access door..-
22 opens outward from the frameforaccess. to a.season-: mg 011 container insertable into the bottom of frame .12.
Access door 24 opens forwardly forconvenience in filling a raw popcornfbin withinthe' frame,:. .ocltab le door or drawer 26 may be provided for safeguarding cash. An electrical outlet 28 may be provided for powering accessory equipment. An access door 30 is provided and hinges for outward swinging movement to provide access to the mechanical equipment located in the bottom of the frame and for removal of the old maids bin and condensate pan.
Display case 16 includes a front wall defined by a pair of outwardly pivoting transparent doors 32, 34, providing access to the interior of the case for bagging popcorn and cleaning purposes. A forward pivoting door 36 is also provided below the transparent doors for removing popcorn. The display case sides 38, 40 and back 42 are preferably transparent for customer attention and product appeal. Referring to FIG. 3, a suitable screen 44 is provided in the bottom of the display case to pass the fines and old maids downwardly into a chute leading into a bin for subsequent removal. Popping pot 18, described in greater detail hereinafter, delivers the popped corn into the display case through cone 46 in an attention getting shower onto the bottom of the case.
Upper portion 20 includes on its front face a control panel 48 including the selector knobs and indicator lights to be presently described. A lockable control cover panel 50 is slideable along the front face of panel 48 and, when locked in position, prevents unauthorized usage of the machine.
Raw corn storage and conveyor Referring to the cross-sectional elevation view of FIG. 4, elements of the raw corn storage and conveyor system are illustrated in greater detail. A large corn supply bin 52, capable of storing up to 100 lbs. of corn, is mounted in a lower portion of frame 12. The bin is provided with a trough-shaped bottom 54 directing the raw corn downwardly into air-conveyor device 56 which automatically delivers a supply of corn, as required, upwardly into corn hopper 58 disposed in upper section 20 above pot 18. Air conveyor 56 includes a suitable blower 60 driven by a preferred electric motor 62. The blower draws inlet air through opening 64 and directs it through transverse conduit 66 upwardly through vertical conduit 68 passing along the rear wall of the display case, as best illustrated in FIG. 12. Corn from bin 54 is delivered intermittently through the air stream from the blower by metering device 72 operated by a signal from the control circuit indicating that a resupply of hopper 58 is required. Metering device 72 may be any suitable valving arrangement, and preferably comprises a conventional scroll or anger conveyor horizontally axised with an inlet opening at 74 communicating with bin 54 and with an outlet at 76 communicating with throat section 78 comprising a section of the air stream conduit. Metering motor 80 driving the auger is actuated responsive to a corn resupply signal until terminated responsive to corn level sensors in hopper 58 indicating that a sufficient quantity of corn has been supplied for an additional charge of corn into the pot.
The upper section of vertical conduit 68 passing through display case 16 is preferably formed of a transparent material such as plastic affording an attractive display ofcorn delivery for public viewing.
With the corn supply in bin 52 at the lowermost portion of the machine, reloading through access door 24 is more easily and conveniently accomplished as opposed to a corn supply location above the popper. At the same time, the lower corn storage location is cooler and thus does not dry the corn as fast, as opposed to a location closer to the warmer portion of the machine near the popper. The air feed is a simple and inexpensive method of deliverying a relatively small amount of corn intermittently on a demand basis. Neither the auger metering device nor the air conveyor itself are injurious or damaging to the corn kernels.
6 Corn and salt hopper 58- Referring to FIGS. 7 and 8 hopper 58 is shownin greater detail. In the preferred form, the hopper is divided into a corn reservoir 82 and salt chamber 84 by means of center partition 86, although the two supply reservoirs could be separated into individual chambers. The corn and salt supplies are in juxtaposition to simplify and improve injection of the charges into the popper, as described hereafter.
Corn reservoir 82 is closed at the top by upper Wall 90, at the sides by partition 86 and side wall 92, and at the ends by end walls 94, 96 converging together below to define a narrowed throat section 98. The hopper is mounted by means of base 100 on top of a support plate 102 separating display case 16 from upper section 20. Throat section 98 of the hopper is in vertical registry with an opening 104 provided in plate 102, and this opening in turn communicates with popping pot 18 upon a fill cycle of the rotary valve apparatus 106 of FIG. 18.
An inlet opening 108 is provided in end wall 94 of the corn reservoir communicating with conduit 70 of air conveyor 56. An outlet 110 is provided in the other end wall 96 and communicates with an air outlet conduit 112. A screen 114 is provided over opening 110 to retain the corn within the reservoir. During operation of the air conveyor, corn entering the reservoir through opening 108 refills the reservoir while the conveying air exits through opening 110.
The level of corn in the reservoir is sensed by a pair of capacitor plates 116, 118 mounted at the desired level within the reservoir to respective side wall 92 and partition 86. As the corn fills within the reservoir and occupies the space between the capacitor plates, the capacitance across the plates changes. This actuates the control circuit through leads 120, 122 for terminating operation of the corn meter motor, and energizes the corn indicator light for continuation of the cycling operation in a mannot described hereinafter.
During injection of the corn charge into the pot, the valve hole or opening 396 of valving apparatus 106 moves into alignment with hopper throat section 98. The corn is swept into the pot from the hopper by both the action of gravity and a stream of air fnom air conveyor outlet 79 moving down through throat section 98 into the pot and exiting through the lower opening 124 of cone 46, as best seen in FIG. 10. The continued air pressure in the hopper from air conveyor 56 insures an air flow into the pot preventing any effluent from entering and fouling the hopper. This continued air fiow, although principally effective during filling, provides insurance of a.
positive pressure in the hopper to prevent efiluent leakage at all times.
After the corn has been injected, a charge of salt is then introduced into the pot from salt chamber 84. The salt chamber is closed at its sides by partition 86 and side wall 126, and at its ends by end walls 94 and 96 coextensive with the corn reservoir. The top of chamber 84 is provided with a fill hole 128, and the bottom is confined by housing provided with an opening 132 communica-ting with a charging valve 134. A salt bin 136 is pivotally mounted at 138 within chamber 84. Bottomwall 140 of the bin slopes downwardly from the pivot point to a relatively small spout or opening 142. The spout is adapted to move into opening 132 and act as a funnel for filling the charging valve 134. Bin 136 is yieldably biased by suitable means such as spring 144 upwardly within the salt chamber, or clockwise as viewed in FIG. 8. A normally closed switch 146 is mounted on chamber wall 126 and is adjusted for contact with salt bin 136 for opening when the bin is in its upper position, and for closing when the bin pivots away.
Salt bin 136 preferably has a capacity on the order of 6 /2 pounds, adequate for from 75 to 100 pops. With the bin filled with salt, it will pivot counter-clockwise by gravity against the force of spring 144 to close switch 146,
which in turn .signals the. control, circuit to light the salt indicator light and condition the; circuit for continued cy- 'clin'g': A's saltis gradually used up so that an insufiicient supply reinains inthe binifor continued popping, spring '1 44 "'will overcome thelweiglit of the bin", pivotit clock"- and thereby 'opeii switch 146 to signal the control circuititb-stop' the -fill cycle and'tu'rn 01f the saltlights' so that 'th'e s'altsupplyi must be replenished:
Charging valve 134 comprises a spool-valve 148' axially slidable in housing 130 underneath salt chamber openir'ig'132 'bythe action of solenoid 1*50 operatively connected With valve stem 152. A return spring 154 is provided at the'opposite end of valve stem 152 for returning valve 134 to the position illustrated for receiving a supply of salt from bin 136. In this position, salt drains from spout 142 through opening chamber opening 132, and into cavity 156 formed between the lands of the spool valve. The volume of this cavity is selected to provide sufiicient salt for one pop. The salt draining through spoutv 142 will automatically stop after the cavity is filled to a level just above the lower edge of the spout.
During a salt charging or filling operation after the charge of corn has been injected into the pot, solenoid 150 is actuated by the control circuit to move spool valve 148 to the left so that the salt in cavity 156 is swept into the pot by gravity and the air current previously described. A shield 158 comprises a section of a cylinder secured at one side to partition 86, and is adapted to slideably receivespool valve 148. The lower section of shield 158is cut away at 160 to allow the salt to drop through by gravity and be swept along by the air stream. This air injection of the salt into the pot serves to dry the salt and prevent fouling or sticking or the component elements, and at the same time insures that all of the salt in each charge completely enters the pot for popping.
Seasoning oil pump system The seasoning oil pump system includes a pump assembly 160 disposed Within a seasoning oil bucket or vessel 162 positioned at the bottom of frame 12 for easy replacement, as illustrated in FIGS. 4 and 13. The pump assembly is adapted to intermittently pump a supply of oil on a demand basis from bucket 162 upwardly through feed line 164 into oil reservoir 166 mounted above support plate 102 and positioned for injecting an oil charge into pct 18, as explained hereinafter. The preferred seasoning oil would be coconut oil, although other conventional popping oils may be used with the invention.
The seasoning oil useful with the invention solidifies at room temperature. The invention provides a means for melting a small quantity of the oil required for a number of initial popping cycles without the necessity of melting the entire contents of the oil bucket. This provides a more rapid start-up of the machine, as well as requiring less power.
Pump assembly 160 is adapted to move downwardly on the surface of the solidified oil while guided by a telescoping feed line 168 and telescoping support 170, as best seen in FIG. 14. A bracket 172 mounted on frame 12 supports the outer telescoping member 174 of feed line 168:,'andf outer, telescopingmember 176 of support 170 Feed'line 168 is a rigid conduit secured at its lower end to pump u' n it'f178", and slideably received at its upper end withinputer telescoping member 174. Similarly, telescopi g support 170 is mounted at its lower end to the pump unitan'dj' is slideably received at its upper end with' tele scoping member 176. An O-ring seal 180 is mounted within the lower inner periphery of member 174 to proafluid-tight seal with feed line 168. The telscoping tu be elim inates the requirement for flexible h osing which othe'rwise could kink and interfere with pump help n abs s en in IG- 5- he Pu p i z r nhy ansuitable electric, motor mounted for ovement Cwith the pump housingaon an uPWA dl-y. ergtending bracket 188. The motor ,ismounte d at a "elevatitn-rv abQ e the spump unitflsothat the motor is clear,.,of the melted oil after the pumphas dropped toits lowermostposition. The pump is driven from the motor by asuitabledriye shaft, not. shown, extending along bracket 188.
A lift knob orhandle 190, ros. 4 and 13 ,-15, to bracket 188 and is slideable in a vertical guideway 192 formed in a plate 194 secured to frame 12. when it is desired to remove or. insertan oil bucket 1 62, lift handle is raised until the lower end of pump unit 7 8 clears the bucket. With thenewbucketin placethe is lowered until it rests on the seasoning .oil within he bucket.
The room temperature, solidified seasoning oiLis 1? $51 for pumping by heating elements 1 96Qand 19 8, which may be conventional electrical resistance-type heating. ele ments in suitable tubing'or the like andconnected in tih e control circuit. Lower heating element 196 i sifcoiled ina serpentine path for melting oil. atfithe base of the pump unit. The purpose is to bothrnel't' 'oil around pump inlet 184 for rapid start-up, andialsoto melt .a, path d wn through the seasoning oil a'sm oil is consumed and, the gradually moves downwardly; Heating. element" 198 ezg tends vertically in a serpentine pathor the like along telescoping feed tube 168, and may be of the conventional electrical resistance-type heater. The purpose of heater 198 is to both heat the oil within feed tube 168, which may have solidified after a lengthoftime following-a, previous pum ing cycle, and also to .melta path': through: any solidified oil which may be above pump housing 1'82 dur,- ing start-up so that pump operation can draw air d own, thus preventing pump cavitation. After machine l operap tion progresses for a number of pops, theheatcr gradually melt the entire.oi1- inthe bucket so that the pump. moves downwardly through the oil to the bottom of the bucket. y x
A pair of normally closed limit switches. 200 202 are mounted on frame 172 adjacent telescoping support 1710 Switch 200 is connected to cut off the circuit to pump motor 532, and switch 202, resets the operating cycle, when the pump unit is raised to its uppermost position. A switch-operating cam 204 mounted at the lowerend bracket 188 is in registry with and;operat es the switches 200, 202 in its raised position. This provides a safe fty feature so that the pump is automatically turned 01f when raised out of the bucket. i
The oil is pumped under pressure upwardlyithr'ough outer telescoping feed member 174 into fiting206 con nected with the lower end of feed line 164, as'illustrated in FIG. 13. Feed line 164' guides the oil upwardly along the rear corner post ofthe display case and across to inlet 208 of oil reservoir 166. The overflow from oil "reservoir outlet 210 is directed through overflow conduit 2'12. adjacent to the inlet conduit, down the corner post of the play case and directly over the oil bucket which 'itemptie's Oil reservoir and metering system""" Referring to FIGS. 16 and 17, oil'reservoir166 includes a housing 216 defining a'cavity or sump 21-8Cclose'd at its upper end by cover plate 220. Reservoir inlet 208 is con nected with oil feed line 164 by means of'fitting 222, and communicates with a transverse 'bore' 224 formedin the housing. Bore 224 in turncommu'nicates With a hollow level-adjusting tube-226 slideably' mounted in the} housing in" vertical bore 228'. Adjusting tube 226 isclos'e'd" at its upper end and retains a compression spring 230 func tioni'ng to yieldably urge tube 226"upvvardly draining hole or opening 232 "formed in the side of tube 226 prbvides communication between reservoir cavity 218*, the
interior of tube 226, and bore 224." j a An adjusting mechanism 234 is provided to selectivelyadjust the vertical position of tube 226 and thereby adjust the level of drain 232. Adjusting mechanism 234 comprises an adjusting knob 236 adapted to turn shaft 238 threadably mounted in cover plate 220 directly above the end of tube 226. A pivoting shoe 240 mounted on the end of shaft 238 bears against the end of tube 226. A lock nut 242 is provided to lock the shaft and level adjustment tube in the selected position. The adjustabl drain level of the invention is more accurate in charge measurement than previous methods employing pumps, etc. where temperature variation or inaccurate pump shut off affects filling volume. Also, the invention provides a degree of safety in automation wherein only a measured amount of oil can be displaced into the pot on each cycle without the possibility of overfilling or overpumping.
l Reservoir outlet 210 is connected with overflow conduit 212 by means of fitting 244 and communicates with the reservoir cavity through bore 246.
A spring-loaded ball check valve 248 is provided to prevent trapped seasoning oil from hardening in the reservoir during shut-down. Valve 248 includes a ball 250 yieldably urged upwardly by means of spring 252 within bore 224. A drain plug 258 is provided for retaining spring 252 in position. Check valve 248 is normally held in open position duimg shutdown by means of drain shaft 260 contacting ball 250 at its end and yieldably urging the same downwardly by means of spring 262 mounted below drain shaft housing 264. Drain shaft 260 includes an upward extending portion 266 slideably mounted in housing 264 and connected at its upper end 268 with electrically operated solenoid 270. Throughout the operating cycles of the machine solenoid 270 is operated to draw drain shaft. 260 upwardly permitting drain valve 248 to close. During machine shut-down, solenoid 270 is de-energized permitting the spring to urge drain shaft 260 downwardly andopen' valve 248. Any oil remaining in the reservoir w'ill drain through the valve and thus cannot solidify in the reservoir. This prevents the reservoir and metering device from' malfunctioning and permits rapid start-ups without the requirements of heating the entire metering assembly and solidified oil.
A dump valve "assembly 272, FIG. 17, is provided to direct the metered amount of oil into the popper at the cycle time as influenced by the control circuit. The dump valve assembly includes a valve head 274 carried on valve stem 276 and yieldably urged into sealing engagement with valve seat 278 byspring means 280. The valve stem in turn is connected at 282 withelectrically operated solenoid 284. When energized, solenoid 284 lifts valve head 274 from seat 278 to open communication between the reservoir cavity and bore 286 in registry with an oil inlet opening 288 formed in plate 102. The oil inlet is at a radial/position clearing rotary valve apparatus 106 for directing oilinto pot 18 by gravital flow.
An oil level sensing device 290 is provided to sense oil level in the reservoir and signal the control circuit for cycle functions. In the preferred form, the sensors comprisethreehorizontal, vertical spaced capacitor plates 292, 294 and 206 positioned at predetermined levels within the reservoir. Electrical leads 300, Y302 and 304 attached to respective condenser plates signal the control circuit as the oil level rises above 'atleast two of the plates.
Assuming that dump valve 272 is closed and check valve 248 isclosed for cycling,-the control circuit will signal pump 178 to pump oil through inlet 208 and drainhole 232 to fill the reservoir. As the oil level gradually rises to a lev'elwhich covers both plates 292 and 294, the capacitors signalthe control-circuit to start the popping cycle. The pump continues to fill the reservoir until the level rises above plate 296, and this signals the control circuit to" terminate'the-pumping operation- Should the pump fail to stop for any reason the overflow will harmlessly return tothe'oil bucket through outlet 210 and conduit 212. Also,
the control circuit is timed to shut 01f after 10 seconds of operation to prevent damage to the pump should the pump run dry. It has been found that approximately 5 seconds is suflicient time for the pump to fill reservoir 166.
After the control circuit has signaled the pump to stop, oil will start to drain backwards through the drain hole 232, bore 224, inlet 208, and feed tube 164 to pump 178. Pump 178 is provided with a conventional bypass opening, not shown, through which this oil will drain. The oil continues to drain until it reaches the lower portion of drain hole 232. The amount of oil in the reservoir is now at the pre-selected amount which has adjustably been set into the metering device through adjustment of mechanism 234. Following this, the control circuit signals solenoid 284 to operate for opening dump valve 272 and permit this quantity of oil to drain into the pot. In the preferred embodiment, the maximum extent of downward travel of level adjustment tube 226 is such that drain hole 232 is positioned so that a minimum setting of 4 ounces of oil will be injected. The upper extent of tube 226 travel provides a maximum of 10 ounces of oil.
Popping pot and discharge apparatus Popping pot 18 is positioned in the display case below support plate 102 for receiving the corn, salt and oil charges, for discharging steam and waste oil upwardly into condenser outlet 306 for delivery to condensing system 308, for receiving inlet air through evacuation inlet 310, and for evacuating popcorn through outlet conduit 312 and downwardly into the display case through tube 46, as best seen in FIG. 10. Pot 18 comprises a bottom hotplate and agitator assembly 314 pivotally mounted at 316 to a housing 318, shown as cylindrical, mounted below support plate 102 by suitable means, such as bolts 320. The lower edge of the housing is mounted in sealing engagement with a groove 322 provided in angular support rim 324. Evacuation conduit 312 extends through an openmg 326 in housing 318 downwardly to an opening 328 radially centered in the pot and spaced above hot plate 314 at a height sufiicient to permit popped corn to be swept upwardly through the conduit by a stream of air. Conduit 312 extends outwardly from the pot through an opening 330 provided in upper cylindrical portion 332 of cone 46, where it angles to a downwardly facing discharge outlet 334. Corn exiting from the pot through conduit 312 cascades downwardly through cone opening 124 into the display case.
Hot-plate and agitator assembly 314 includes a casting 336 of flat, circular configuration embedded with a suitable heating element 338, such as a conventional electric resistance element connected by suitable leads, not shown,
with the control circuit. A lower cover plate 340 is secured beneath the hot plate as a precaution against injury to the operator. Upper annular rim 342 of casting 336 is in sealing engagement with housing rim 324 preventing escape of steam and waste oil from the pot. A locking mechanism 344 mounted on rim 342 at a diametral positron from pivot 316 secures hot-plate assembly 314 against housing nm 324 throughout a series of popping cycles. The locking mechanism prevents unauthorized or accidental opening of the pot during popping, inasmuch as it is not necessary to open the pot for either charging or popcorn removal. For cleaning purposes, locking mechamsm 344 15 released permitting hot-plate assembly 314 to pivot downwardly at 316.
bly mounted on an upwardly extending spindle 350 supported in a recessed portion 352 of casting 336. A plurality of outwardly extending, generally flat blades 354, 356 are mounted for rotation with the hub in a clockwise direction as viewed in FIG. 11. The sharpened forward edge of each blade has a radially outward forward rake with respect to the axis of rotation. This provides a radially inward sweeping action to move the popcorn towards hub 348 for more efiicient evacuation through conduit 312. The lower base portion of hub 348 is provided with an outwardly flaring skirt 358 functioning to direct the stream of air:upwardly into conduit opening 328 during corn evacuation.
lAgitator assembly 346 is rotated by drive assembly 360 extending downwardly from above the pot. The drive assembly includes a shaft 362 having a preferred hexagonal cross-sectional configuration and slideably looking with a hexagonal female socket 364 provided at the upper end of agitator hub 348. Shaft 362 is spring-loaded from above by suitable means such as compression spring 366 mounted within a sleeve 368. Sleeve 368 in turn is secured to a broached hexagonal nut 370 keyed for rotation with drive shaft 372 extending downwardly through a quill shaft 374 of drive assembly 376 provided for operating rotary valve apparatus .106. Drive shaft 372 is driven from a preferred electric motor 378 during the popping cycle by suitable means, such as a worm gear arrangement, not shown. The lower end 382 of hexagonal shaft 362 projects through an opening 384 of the evacuation conduit, and is aligned with agitator socket 364 for driving engagementwhen hot-plate assembly 314 is closed, as illustrated in FIG. 10. When the pot is opened for cleaning, downward pivotal movement of the hot-plate and agitator quickly uncouples drive assembly 360 at the socket connection. 'When the hot plate is returned and locked in place the shaft and socket will lock in driving engagement where there is correspondence between their angular positions. If shaft 362 does not engage in the socket, it is urged upwardly against the spring which forces them in locking engagement upon start-up of agitator motor 378. As a result, any angular or vertical misalignment between the shaft and mating socket will not prevent engagement of the agitator drive, thus simplifying opening and closing of the pot for cleaning.
Rotary valve apparatus The rotary valve apparatus 106 provides an accurate valving of the various processes into and out of pot 18 in timed relationship with a pre-determined program under influence of the control circuit. The valve arrangement of the invention provides a mechanical memory to assist the electronic system to prevent loss of cycle'position during power failure or accidental shut-01f. The valve apparatus includes a generally flat valve plate or disc 386 mounted for rotation with drive assembly 376 within the top H of pot housing 318. A mounting plate 388 supports the valve plate to a flange 390 of quill shaft 374 by suitable means, such as a plurality of mounting screws or the like. Valve disc 386 extends outwardly with a radius suflicient to cover aseries of openings provided in the top of pot housing 318 and support plate 102-. As illustrated in FIGS. and 18, these openings include a condenser outlet opening 392 connected with condenser conduit 306, an air inlet 394 connected with evacuation inlet conduit 310, and opening 104 connected with throat section 98 of corn and salt hopper 58. An opening or disc hole 396 is formed in disc 386 uncovering openings 104, 392 and 394 in accordance "with the circuit program. A screen 393 covers opening. 392 and prevents corn from entering conduit 306.
Valve drive assembly 376 includes a gear 398- keyed to quill shaft 374, which in turn is journaled for rotation within an upstanding sleeve 400 mounted above opening 402 provided in support plate 102. Gear 398 is driven by suitable means such as an electric motor 404 mounted on bracket 380 and in driving connection with the gear through a suitable pinion gear 406, or the like, as illustrated in FIG. 9.
Different processes of the control circuit are triggered by a plurality of switches actuated responsive to gear 398 a 12 rotation, and therefore in exact timed relationship with rotation of valve plate 386. Referring to FIG. 18, a start switch 408, a fill switch 410, a cook switch 412, and an evacuation switch 414 are mounted on a suitable bracket, not shown, around the periphery of gear 398. Start switch 408 is positioned on a radial line bisecting the angle between fill opening 104 and evacuation inlet 394. Fill switch 410 is positioned on line with fill opening 104. Cook switch 412 is positioned on line with condenser outlet opening 392. Evacuation switch 414 is positioned on line with evacuation inlet 394. These switches are actuated by suitable operating means on gear 398, shown as a switch operating roller or cam 4|16 attached to the gear and positioned on a line centered on disc hole 396.
Referring to the schematic circuit diagram of FIG. 19, switches 408, 410, 412 and 414 are illustrated connected in the control circuit for operating the circuit relays, timers and indicator lights, as explained in greater detail hereinafter.
Evacuation of effluent and popped corn alignmentwith evacuation inlet opening 394, blower 418 is energized to draw intake air from cone 46 and direct it into the pot through conduit 310 and opening 394. A; deflector plate 430, preferably of a fiat, circular configuration, is mounted within the pot by suitable means, such as a bracket 432 secured to the outside of conduit 312 at a position spaced directly below inlet 394. Deflector, plate 430 functions to direct the incoming air stream outwardly and downwardly around the inside periphery of the pot in a sweeping motion. Thin enhances the efliciency of popcorn evacuation so that the air stream sweeps the popcorn across the bottom of the hot-plate, upwardly into evacuation conduit 312, and downwardly through cone 46 into the display case. The stream of air issuing from outlet 334 in cone is recirculated and drawn upwardly. through the blower intake. During this evacuation cycle,
valve plate 386 closes olf condenser outlet 392.
After a filling cycle with the corn and salt charged" into the pot, motor 404 indexes valve disc 386 until valve hole 396 opens communication with condenser outlet 392,
and at the same time cam roller 416 actuates switch 412- let 392 into condenser system 308. During the cook cycle, motor 404 stops the valve disc with itsopening at the condenser outlet position until the corn in popped and the control circuit initiates the evacuation cycle.
Steam and waste oil condensing system I Condensing system 308 is adapted to .draw the steam and waste oil effluent from the pot by vacuum, and to:
condense the same by self-cleaning action without escaping into the surrounding room. The condenser system comprises an upstanding shell 434 mounted at the rear of i frame 12. Effluent from the pot is directed through conduit 306 into an upper inlet header 436 communicating with a plurality of downwardly extending heat exchange" tubes 438. The tubes 438 communicate at, their lower end with a chamber 440 for reversefiow upwardly along aplurality of upwardly extending. heat exchange tubes 442 discharginginto outlet header. 444 and outlet tube 446.
-A-partition 448 divides shell 434 into two air channels 450 and.;452 enclosing respectivetubes 442 and 438. Cooling air froma condenser blower 454, as best seen in FIG. 4, is supplied from within lower section 14 of the machine and directed into inlet opening 4560f shell 434. The cooling air is forced-upwardly for cooling and condensing the steam and waste oil..Opening 458 in partition 448 combines the flow from channel 452 with that of channel 450 for delivery through a venturi or narrowed throat section 460 ,adjacent the discharge end of tubes 442. The increased air flow and lowered static pressure at the venturi creates a vacuum within tubes 442 acting to draw the steamand waste oil through the condenser tubes from the pot i'n'theflow path illustrated in FIG. 5.
.Condensed steam'and oil droplets forming on the inside surface of the condenser tubes drop downwardly by gravity to collect on the bottom of chamber 440 where it 'drains through outlet 462 into a removable condensate drain .pan 464.
FIG. '20 illustrates'a modified form embodying'a steam condenser, illustrated generally at 466. Condenser 466 replaces outlet conduit 306 betweencondenser outlet 392 and condenser header 436 in the preferred form of FIG. 6, and functions to immediately condense steam as it leaves the pot. The water condensate is collected and drained away preventing its-return to the pot. This results in a-dryer popcorn havingimproved flavor and tenderness;
Condenser 466 comprises an upwardly extending tube section-468 mounted over condenser outlet 392 on support plate 102. Conduit section 470 encloses at one end upper lip 472 of the, tube and extends downwardly therefrom to an outlet474 mounted to the inlet of condenser header 436 by. suitable fasteners provided on mounting flange 476. A dome or cap 478 is mounted above an opening 480 provided in conduit-470directly above the tube. Tube lip 472 is radially spaced inwardly from conduit end portion 482to.define a collecting gutter 484. A conical screen 486 mounted above tube lip prevents kernels of corn from entering the condenser air stream. In operation, steam and waste oil particles drawn from the pot by the vacuum created-in the condenser during a cooking cycle enters tube- 468 and impinges'on both screen 486 and the inner surface of ,cap 478.- The lower temperatures of these elements functions to condense the steam which collects and runs downwardly intogutter 484, the lower surface of conduit 470,;and through tubes 438 of condenser 308 for deliveryr'into condenser outlet drain 462. After the cooking cycle, when the condenser outlet is closed by the valve plate; the elements of condenser 466 lose the heat received from the condensed steam'and cool down for the following cooking and condensing cycles.
Removal of Old Maids .Inthe form ofv the invention illustrated in FIGS. 1-4 the old maids or unpopped kernels are removed from pot .18 along with the popcorn and are delivered into display. case 16 where they fall onto screen 44. The kernels either 'dr'opthrough the screen into fine collector tray 488 unassisted, or else are-scrapedonto the screen by the operator., From tray 488 thekernels aredirected through fine chutev 490 downwardly into removable bin 492 provided at the bottom of the frame. v I
In the modified form illustrated in FIG. 21, an alternate; old jmaid removal system is indicated generally at 494., This system comprises a kernel trap device 496 including a lower tubular portion 498 extending downwardly through an opening in support plate 102 into the display'case" and opening underneath at 499. An upper I tube extension 500 projects. above plate 102 into upper machine sectionl 20. 'Ehetrap may extend through an opening inIQPncover 502 with a transparent top cover or dome504 of a suitable materiaL'such as-Lucite plastic.
This provides an attractive display of popcorn moving upwardly during an evacuation cycle. Popcorn issuing from the pot through evacuation conduit 312 enters the trap through inlet connection 506 and is deflected upwardly by means of partition 508. This partition comprises a vertical section of a cone removably attached within trap 496 and with its small end adjacent inlet 506 and its large end 510 opening upwardly within the tube. A lower section 512 of the partition is lockably hinged at 514 for cleaning purposes and extends downwardly in abutting relationship with a tubular chute 516 extending downwardly from the trap to direct the old maids into a bin 492 for subsequent removal.
In operation during an evacuation cycle, the popped corn and old maids are directed upwardly through conduit 312, then into opening 506 of the trap. The popcorn is deflected upwardly by partition 508 and carried in the channel between the tube and partition by the air stream until it cascades over upper end 510 and falls downwardly into the display case. The velocity of the air stream is high enough to blow the popcorn upwardly but insuffie cient to lift the old maids, which instead are carried by gravity downwardly through opening 518 into chute 516.
As a result, the old maids are automatically removed from the popped corn.
Automatic control circuit contacts of start switch or button 526 and temperature control switch 528 adapted to regulate plate temperature preferable at 410 F. Power at VAC is provided at 530 for operating various control elements including agitator motor 378, valve disc motor 404, corn meter motor 80, seasoning pump motor 532 operating pump 178, motor 420 for powering emptying or evacuation blower 418, salt fill solenoid 150, and total pop counter 536. The voltage from source 530 also operates power supply 538 providing a suitable direct current control voltage, such as 26 VDC. This voltage powers the R.F. generator 540 connected with both corn level capacitor plates 116, 118 and seasoning level plates 291, 294 and 296. This DC voltage further powers the number of pops selector control 542 through relay 544 and provides an input 546 pump motor 532 to fill oil reservoir 166 responsive to a signal from seasoning level condenser plates 292, 294
and 296. Upon completion of the oil filling. cycle, a signal is directed from switch 554 into and switchv 552.
Salt level switch 146 provides a signal to'ffand switch 552 for continued cycling only if sufiicient salt is in bin .136 for the followingpopping cycle. The number of pops selector 542 also provides a signal into switch552 for recycling of the popping cycle only wherev the number of pops selected by the operator exceeds the total pop count received at input 557 following each energization of fill switch 410. The recycle signal from selector 542 also triggers operation ofcorn'level detector 548.
The'seasoning temperature is measured by low *temperature limit switch 558 which directs a signal to'both seasoning level detector/ switch 544 and switch 552 when the temperature of the oil is high enough for pumping
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US4152974A (en) * 1978-06-16 1979-05-08 National Presto Industries, Inc. Hot air corn popper
US5309825A (en) * 1993-03-04 1994-05-10 Show-Pop International, Inc. Popcorn vending machine
US6000318A (en) * 1994-11-28 1999-12-14 Gold Metal Products, Inc. Automatic popcorn popper with thermal controller
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US5885641A (en) * 1994-11-28 1999-03-23 Gold Medal Products Co. Automated corn popper
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US6412395B1 (en) 1994-11-28 2002-07-02 Gold Medal Products Company Automatic popcorn popper with thermal controller
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